Two-speed drive module

ABSTRACT

A drive module that includes an electric motor, a differential assembly with a differential input member and a pair of differential output members, a multi-speed transmission assembly, which transmits rotary power between the electric motor and the differential input member, and a pair of axle shafts that are each coupled to an associated one of the differential output members for rotation therewith. The multi-speed transmission assembly and includes a housing, a two-speed planetary transmission stage, a plurality of clutches and a transmission output member that provides rotary power to the differential input member. The two-speed planetary transmission stage has an input sun gear, which is driven by the motor, and employs a set of planet gears having compound planet gears that provide a gear reduction between the sun gear and the transmission output member. The clutches are employed to control an overall reduction ratio.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a division of U.S. application Ser. No. 14/159,534filed Jan. 21, 2014, which claims the benefit of U.S. Provisional PatentApplication No. 61/779,780 field Mar. 13, 2013. The disclosure of eachof the above-referenced applications is incorporated by reference as iffully set forth in detail herein.

FIELD

The present disclosure relates to a two-speed drive module.

BACKGROUND

This section provides background information related to the presentdisclosure which is not necessarily prior art.

It is known in the art to provide an all-wheel drive vehicle drive trainthat provides drive torque to the front and rear wheels of a vehicle oneither a full-time basis or a part-time but automatically-engagingbasis. The known full-time all-wheel drive configurations typicallyutilize a transfer case or power transfer unit and a center differentialor coupling to distribute drive torque to a front differential, which inturn distributes drive torque to the set of front wheels, and a reardifferential, which in turn distributes drive torque to the set of rearwheels. The known part-time all-wheel drive configurations typicallyutilize a power transmitting coupling that permits a set of wheels(e.g., the rear wheels) to coast until the other set of wheels (e.g.,the front set of wheels) begin to loose traction.

One drawback of these all-wheel drive arrangements concerns theircomplexity and overall cost. Not only are the components of theall-wheel drive system relatively complex and costly to manufacture andinstall, the associated vehicle architecture is frequently more complexdue to the common practice of vehicle manufacturers to offer vehicleswith a standard two-wheel configuration and an optional all-wheel driveconfiguration. In this regard, it is frequently necessary to modify thevehicle fuel tank and/or relocate the spare tire of the vehicle toincorporate a conventional four-wheel drive system into a two-wheeldrive vehicle.

One proposed solution involves the use of wheel hub motors. In thesesystems, relatively large electric motors are placed within thecircumference of two or more of the vehicle wheels. As wheel hub motorsare relatively large in diameter, the size of the wheel tends to berelatively large (i.e., 18 inches or greater). Consequently, wheel hubmotors may not be practical as when a relatively small wheel size isemployed or where packaging issues, such as the size and location of afuel tank or the location of a spare tire, prevent a wheel hub motorfrom being integrated into the vehicle.

One relatively recent innovation in all-wheel drive vehicles is a drivemodule that employs an electric motor, a transmission and a differentialto selectively drive a set of vehicle wheels. Such drive modules aregaining acceptance with automotive original equipment manufacturers inhybrid vehicles and may at some point be employed as the sole source ofpropulsive power in an electric vehicle. While the known drive modulesare satisfactory for their intended purposes, there remains a need inthe art for an improved drive module.

SUMMARY

This section provides a general summary of the disclosure, and is not acomprehensive disclosure of its full scope or all of its features.

In one form, the present teachings provide a drive module that includesan electric motor, a differential assembly, a multi-speed transmissionassembly, and a pair of axle shafts, the differential assembly having adifferential input member and a pair of differential output members. Themulti-speed transmission assembly being configured to transmit rotarypower between the electric motor and the differential input member. Themulti-speed transmission assembly includes a housing, a two-speedplanetary transmission stage, a first clutch, a second clutch and atransmission output member. The two-speed planetary transmission stagehas a sun gear, a ring gear, a plurality of planet gears and a planetcarrier. The sun gear is the input of the two-speed planetary stage. Theplanet gears are meshed with the sun gear and with the ring gear. Theplanet gears are rotatably mounted on the planet carrier. One of theplanet carrier and the ring gear is the output of the two-speedplanetary transmission stage and is drivingly coupled to thetransmission output member. The first clutch is selectively operable forlocking the two-speed planetary transmission stage such that it operatesin a 1:1 gear ratio. The second clutch is operable for controllingrotation of the other one of the planet carrier and the ring gear. Thetransmission output member is meshingly engaged to the differentialinput member. Each of the axle shafts is coupled to an associated one ofthe differential output members for rotation therewith.

Further areas of applicability will become apparent from the descriptionprovided herein. The description and specific examples in this summaryare intended for purposes of illustration only and are not intended tolimit the scope of the present disclosure.

DRAWINGS

The drawings described herein are for illustrative purposes only ofselected embodiments and not all possible implementations, and are notintended to limit the scope of the present disclosure.

FIG. 1 is a schematic illustration of an exemplary vehicle having adrive module constructed in accordance with the teachings of the presentdisclosure;

FIG. 2 is a section view of a portion of the vehicle of FIG. 1,illustrating a portion of the drive module that includes an electricmotor and a multi-speed transmission assembly;

FIG. 3 is an enlarged view of the multi-speed transmission assembly;

FIG. 4 is an enlarged portion of FIG. 3;

FIG. 5 is a section view of another portion of the vehicle of FIG. 1,illustrating a portion of the drive module that includes a differentialassembly;

FIG. 6 is a left side elevation view of a portion of the vehicle of FIG.1 illustrating the drive module in more detail;

FIG. 7 is a section view of a portion of the drive module, illustratinga hydraulic pump in more detail;

FIG. 8 is a schematic illustration of a portion of the drive module,illustrating a hydraulic circuit;

FIG. 9 is a section view of a portion of another drive moduleconstructed in accordance with the teachings of the present disclosure;

FIG. 10 is an enlarged portion of FIG. 9;

FIG. 11 is an enlarged portion of FIG. 10; and

FIG. 12 is a view similar to that of FIG. 2 but depicting anotherexample of a drive module constructed in accordance with the teachingsof the present disclosure.

Corresponding reference numerals indicate corresponding parts throughoutthe several views of the drawings.

DETAILED DESCRIPTION

With reference to FIG. 1 of the drawings, an exemplary vehicle having adrive module constructed in accordance with the teachings of the presentdisclosure is generally indicated by reference numeral 10. The vehicle10 can include a front or primary driveline 14 and a rear or secondarydriveline 16. The front driveline 14 can comprise an engine 18 and atransmission 20 and can be configured to drive a front or primary set ofdrive wheels 22. The rear driveline 16 can comprise a drive module 24that can be configured to drive a rear or secondary set of drive wheels26 on an as needed or “on demand” basis. While the front wheels 22 areassociated with the primary driveline 14 and the rear wheels 26 areassociated with the secondary driveline 16 in the present example, itwill be appreciated that in the alternative, the rear wheels could bedriven by the primary driveline and the front wheels could be driven bythe secondary driveline. Moreover, while the drive module 24 has beendepicted in this example as being configured to drive a secondary set ofdrive wheels on a part time basis, it will be appreciated that a drivemodule constructed in accordance with the present teachings could beemployed to drive a (front, rear or other) set of drive wheels (e.g., afront or set of wheels) on a full-time basis, either as the sole meansof propulsion for the vehicle or in conjunction with another means ofpropulsion. The drive module 24 can comprise a drive unit 30, a pair ofaxle shafts 32, and a controller 34.

With reference to FIG. 2, the drive unit 30 can comprise a housing 40,an electric motor 42, a multi-speed transmission 44, a differentialassembly 46 (FIG. 1), a hydraulic pump 48 (FIG. 1), and a park pawlmechanism 50.

The housing 40 can define a structure to which the other components ofthe drive unit 30 are mounted. The housing 40 can be formed of two ormore housing elements that can be fixedly coupled together, such as viaa plurality of threaded fasteners. The electric motor 42 can be mountedto a flange 54 on the housing 40 and can have an output shaft 56 thatcan be disposed along a first rotary axis 58 and received into thehousing 40.

In FIG. 3, the multi-speed transmission 44 can comprise a two-speedplanetary transmission stage 60, a first clutch 62 and a second clutch64. Optionally, the multi-speed transmission 44 can comprise one or morefixed reduction stages or gearsets, such as a first reduction gearset 66and a second reduction gearset 68.

The first reduction gearset 66 can couple the motor output shaft 56 tothe two-speed planetary transmission stage 60. In the example provided,the first reduction gearset 66 comprises a single planetary gearset, butit will be appreciated that any number and type(s) of gearsets could beemployed. The first reduction gearset 66 can comprise a first sun gear70, which can be coupled to the motor output shaft 56 for rotationtherewith, a set of first planetary gears 72, a first planet carrier 74,and a first ring gear 76. The first planet gears 72 can be meshed to thefirst sun gear 70 and the first ring gear 76. The first planet carrier74 can comprise a first carrier body 80 and a plurality of first pins82. The first carrier body 80 can comprise a first body member 84, whichcan be a plate-like structure, and a second body member 86 that cancomprise a shaft portion 88 and a flange 90. A shaft bore 92 can beformed into an end of the second body member 86 through the flange 90and into the shaft portion 88. The shaft bore 92 can be sized to receivethe output shaft 56. If desired, a bearing 94 can be received betweenthe output shaft 56 and the inside surface of the shaft portion 88. Oneor more lubrication passages 96 can also be formed in the shaft portion88. In the example provided, a main lubrication passage 98 is formedlongitudinally through the shaft portion 88, and a plurality of feederpassages 100 intersect the main lubrication passage 98 and extendradially outwardly therefrom.

The two-speed planetary transmission stage 60 can include a second sungear 110, a plurality of second planet gears 112, a second planetcarrier 114, and a second ring gear 116. The second sun gear 110 can becoupled to the shaft portion 88 of the second body member 86 of thefirst planet carrier 74 for rotation therewith. Accordingly, it will beappreciated that the first planet carrier 74 can be an output member ofthe input planetary stage (i.e., the first reduction gearset 66), andthat the second sun gear 110 can be an input member of an intermediate(or output) reduction gear set. The second planet carrier 114 cancomprise a plurality of second pins 122 and a second carrier body 120that can have first and second annular plates 124 and 126, respectively,that can be fixedly mounted to opposite ends of the second pins 122. Thesecond planet gears 112 can be configured to transmit rotary powerbetween the second sun gear 110 and the second ring gear 116. In theparticular example provided, the second planet gears 112 comprise a setof inner planetary gears 112 a and a set of outer planetary gears (notspecifically shown). Each of the inner planetary gears 112 a and each ofthe outer planetary gears can be mounted on the second pins 122 and ifdesired, a bearing 130 can be received between each of the second pins122 and an associated one of the inner or outer planetary gears. Each ofthe inner planetary gears 112 a can be meshingly engaged to the secondsun gear 110, while each of the outer planetary gears can be meshingengaged to a corresponding one of the inner planetary gears 112 a andthe ring gear 116. While the two-speed planetary transmission stage 60has been illustrated and described as having second planet gears 112comprising inner and outer planetary gears, it will be appreciated thatin the alternative, the second planet gears 112 could be configured suchthat each of the second planet gears 112 is meshingly engaged with boththe second sun gear 110 and the second ring gear 116. The second ringgear 116 can be an output member of the multi-speed transmission 44.

In FIG. 4, the first clutch 62 can be any type of clutch that canselectively couple the second ring gear 116 to the second sun gear 110to lock the two-speed planetary transmission stage 60 (i.e., so that thetwo-speed planetary transmission stage 60 operates at a gear ratio ofabout 1:1). In the particular example provided, the first clutch 62comprises a friction clutch having an input member 150, an output member152, a set of clutch plates 154, a pressure plate 156, a piston 158 anda thrust bearing 160.

The input member 150 can be coupled to the shaft portion 88 of thesecond body member 86 of the first planet carrier 74 for rotationtherewith. In the example provided, the input member 150 and the shaftportion 88 are rotatably coupled to one another via a set of matingsplines or teeth, and a thrust washer 166, which is disposed between theinput member 150 and a shoulder on the shaft portion 88, is employed tolimit axial movement of the input member 150 in a direction away fromthe piston 158. The input member 150 can have a radially extendingflange member 170 and an annular first clutch drum 172 that can extendaxially outwardly from the flange member 170. The first clutch drum 172can have a plurality of teeth 174 about its circumference. The teeth 174extend axially and are circumferentially spaced about the exteriorperimeter of the first clutch drum 172. The output member 152 cancomprise an annular second clutch drum 176 that can be fixedly coupledto the first annular plate 124 of the second planet carrier 114. Thesecond clutch drum 176 can have a plurality of circumferentially spacedapart internal teeth 178 that can extend in an axial direction. The setof clutch plates 154 can comprise a plurality of first clutch plates 180and a plurality of second clutch plates 182. The first clutch plates 180can comprise a suitable friction material and can have a toothedinternal aperture that is sized to fit over the first clutch drum 172and drivingly engage the teeth 174. The second clutch plates 182 cancomprise a suitable friction material and can have an annular shape thatis sized to be received into the second clutch drum 176. An outerperimeter of the second clutch plates 182 can be sized to be received inthe second clutch drum 176 and to drivingly engage the teeth 178. Thefirst and second clutch plates 180 and 182 can be interleaved. Thepressure plate 156 can be an annular structure that can be non-rotatablybut axially slidably received onto the first clutch drum 172 and abuttedagainst the set of clutch plates 154. One or more compression springs190 can be received in the first clutch drum 172 and abutted against theflange member 170 and the pressure plate 156. The compression spring(s)190 can be configured to urge the pressure plate 156 axially away fromthe set of clutch plates 154 so that the first clutch 62 is normallydisposed in a condition where rotary power is not transmitted betweenthe input member 150 and the output member 152. The piston 158 can be anannular structure that can be received in an annular cavity 200 in thehousing 40. The annular cavity 200 can be coupled in fluid connection toa source of hydraulic fluid. The piston 158 can carry seals 202 and 204that can sealingly engage inner and intermediate annular walls 206 and208, respectively, in the housing 40. The thrust bearing 160 can bedisposed between the piston 158 and the pressure plate 156.

The second clutch 64 can be configured to selectively non-rotatablycouple the second planet carrier 114 to housing 40. In the particularexample provided, the second clutch 64 comprises a one-way clutch 220and a second friction clutch 222. The one-way clutch 220 can be a typeof self-activating clutch that permits rotation in a first rotationaldirection and inhibits rotation in an opposite rotational direction. Inthe particular example provided, the one-way clutch 220 is a spragclutch having a first race 234, which is non-rotatably coupled to thehousing 40, a second race 236, which is non-rotatably coupled to thesecond planet carrier 114, and a plurality of sprag rollers 238 that caninteract with the first and second races 234 and 236 in a well-known andconventional manner to permit rotation of the second race 236 relativeto the first race 234 in the first rotational direction and to inhibitrotation of the second race 236 relative to the first race 234 in theopposite rotational direction.

The second friction clutch 222 can comprise a set of clutch plates 250,a piston 254, a spring abutment 256, and one or more compression springs258. The set of clutch plates 250 can comprise a plurality of thirdclutch plates 260 and a plurality of fourth clutch plates 262. The thirdclutch plates 260 can comprise a suitable friction material and can havea toothed internal aperture that is sized to fit over the second clutchdrum 176 and drivingly engage axially extending teeth 266 that aredisposed circumferentially about the exterior perimeter of the secondclutch drum 176. The fourth clutch plates 262 can comprise a suitablefriction material and can have an annular shape that is sized to bereceived over the second clutch drum 176. An outer perimeter of thefourth clutch plates 262 can be sized to be received in a cavity 268 inthe housing 40 and to drivingly engage axially-extending teeth 270 thatare spaced circumferentially about the cavity 268. The third and fourthclutch plates 260 and 262 can be interleaved.

The piston 254 can be an annular structure that can be received in anannular cavity 274 in the housing 40. The annular cavity 274 can becoupled in fluid connection to a source of hydraulic fluid. The piston254 can carry seals 280 and 282 that can sealingly engage theintermediate annular wall 208 and an outer annular wall 284,respectively, in the housing 40. The spring abutment 256 can be anannular plate-like structure that can be received on the intermediateannular wall 208. An external snap ring 256 a can be coupled to theintermediate annular wall 208 to inhibit axial movement of the springabutment 256 in a direction toward the piston 254. The compressionspring(s) 258 can be received axially between the piston 254 and thespring abutment 256 and can bias the piston 254 in a direction away fromthe set of clutch plates 250 so that the second friction clutch 222 isnormally disposed in a condition where the second clutch drum 176 is notrotationally locked to the housing 40.

While the second clutch 64 has been described as including a one-wayclutch 220 and a second friction clutch 222, it will be appreciated thatthe second clutch could be configured somewhat differently. For example,the one-way clutch 220 could be omitted altogether. Configuration inthis manner would merely necessitate coordinated control of the firstclutch 62 and the second friction clutch 222 as the two-speed planetarytransmission stage 60 is shifted between speed reduction ratios (incontrast to the configuration that is described above and illustrated inthe accompanying drawings, where coordinated control is unnecessary dueto the self-activating nature of the one-way clutch 220).

As another example, a second actuator, such as a ball-ramp actuator (notshown), could be substituted for the one-way clutch 220. In thisalternative construction, the ball-ramp actuator would tend to expandaxially in response to rotation of the second planet carrier 114 in thefirst rotational direction and exerts an axially-directed force ontosecond friction clutch 222 that tends to compress the set of clutchplates 250 against the piston 254. Rotation of the second planet carrier114 in the second rotational direction, however, tends to collapse theball-ramp actuator in the axial direction so that the set of clutchplates 250 do not tend to inhibit rotation of the second planet carrier114. Accordingly, the ball-ramp actuator can be employed toautomatically inhibit rotation of the second planet carrier 114 when thetwo-speed planetary transmission stage 60 is operated in the low-speedreduction and the electric motor 42 is operated in the predeterminedrotational direction, the ball-ramp actuator can be employed toautomatically permit rotation of the second planet carrier 114 when thetwo-speed planetary transmission stage 60 is operated in the high-speedreduction and the electric motor 42 is operated in the predeterminedrotational direction, and that the piston 254 of the second frictionclutch 222 can be used to control lock-up of the set of clutch plates250 to inhibit rotation of the second planet carrier 114 in the secondrotational direction when the electric motor 42 is operated in arotational direction that is opposite to the predetermined rotationaldirection.

As noted above, the second ring gear 116 is an output member of themulti-speed transmission 44. As such, the second ring gear 116 can beemployed to directly drive the differential assembly 46 (FIG. 1). Forexample, the second ring gear 116 can be formed on or coupled to adifferential case (not specifically shown) of the differential assembly46 (FIG. 1) for common rotation.

With reference to FIGS. 3 and 5, the second reduction gearset 68 can beconfigured in the alternative to transmit rotary power from the secondring gear 116 to a differential case 300 of the differential assembly46. The second reduction gearset 68 can comprise a fixed reduction (asin the particular example provided) or a multi-speed reduction, and/orcould include a mechanism that cooperates with the differential assembly46 to provide torque vectoring capabilities in which equal but oppositevectoring moments are superimposed onto the outputs of the differentialassembly 46.

In the particular example provided, however, the second reductiongearset 68 is a fixed reduction and can comprise a first helical gear310, a second helical gear 312 and an output spur gear 314. The firsthelical gear 310 can be coupled to the second ring gear 116 for rotationtherewith. As such, the first helical gear 310 is the input member ofthe second reduction gearset 68 in the example provided. The secondhelical gear 312 can be meshingly engaged with the first helical gear310 and can be supported for rotation relative to the housing 40 via apair of spindle bearings 320. The output spur gear 314 can be coupled tothe second helical gear 312 for rotation therewith.

The differential assembly 46 can comprise an input ring gear 400, thedifferential case 300, a pair of output members 402, and a means fortransmitting rotary power from the differential case 300 to the outputmembers 402. The input ring gear 400 can be a spur gear that can bemounted to the differential case 300 and meshingly engaged to the outputspur gear 314. The differential case 300 can be rotatably mounted to thehousing 40 via a pair of differential bearings 410. The output members402 can be received in the differential case 300 and can benon-rotatably coupled to an associated one of the axle shafts 32 (forclarity, only one axle shaft 32 is shown in FIG. 5).

In FIG. 6, the park pawl mechanism 50 can include a pawl member 450,which can be pivotally coupled to the housing 40, and a ratchet 452 thatcan be coupled to a member of the second reduction gearset 68 forrotation therewith. The pawl member 450 can be pivoted between a firstor park position, in which the pawl member 450 is engaged between teethof the ratchet 452, and a second position in which the pawl member 450does not contact the teeth of the ratchet 452. It will be appreciatedthat when the pawl member 450 is in the first position, contact betweenthe pawl member 450 and the teeth of the ratchet 452 will inhibit thetransmission of rotary power through the second reduction gearset 68.

With reference to FIG. 7, the hydraulic pump 48 can be configured toprovide lubrication and/or fluid pressure for the activation of thefirst clutch 62 (FIG. 4) and/or the second clutch 64 (FIG. 4). In theparticular example provided, the hydraulic pump 48 comprises alubrication pump 470, which is configured to provide lubrication tovarious components within the drive module 24 (FIG. 1), and aservo-hydraulic unit 472 that is configured to coordinate the operationof the first clutch 62 and the second friction clutch 222. Thelubrication pump 470 and the servo-hydraulic unit 472 could beconfigured in a separate manner so as to circulate different fluids. Inthe particular example provided, the lubrication pump 470 and theservo-hydraulic unit 472 are configured to draw fluid from a commonreservoir 474.

Returning to FIG. 2, the controller 34 can be configured to controloperation of the electric motor 42 and to coordinate operation of thefirst and second clutches 62 and 64. For example, the controller 34 canbe configured to monitor or determine a speed of the vehicle 10 (FIG.1), and/or a rotational speed of a component of the vehicle 10 (FIG. 1),such as a rotational speed of a component of the drive module 24 (FIG.1), and to responsively control the operation of the first clutch 62 tocontrol the gear ratio in which the multi-speed transmission 44 operates(i.e., to selectively lock the second planet carrier 114 to the secondsun gear 110 for common rotation). As another example, the controller 34can be configured to monitor a gear ratio setting of the transmission 20(FIG. 1) and to responsively control the operation of the secondfriction clutch 222 if the transmission 20 (FIG. 1) has been placed intoa reverse gear ratio.

With reference to FIG. 8, the controller 34 can interact with theservo-hydraulic unit 472 to control the first clutch 62 and the secondfriction clutch 222. In the exemplary hydraulic circuit shown, thecontroller 34 is configured to control a rotary direction in which areversible motor 480 of the servo-hydraulic unit 472 drives a reversiblepump 482 that has a first inlet/outlet and a second inlet/outlet.Operation of the motor 480 in a first direction tends to apply hydraulicpressure to the piston 158 of the first clutch 62 and to draw hydraulicfluid from the second friction clutch 222. More specifically, operationof the motor 480 in a first rotational direction operates the pump 482in the first rotational direction, so that the pump 482 draws hydraulicfluid into the first inlet/outlet from the reservoir 474 and aninlet/outlet of a hydraulic cylinder associated with the second frictionclutch 222 through a first fluid conduit and transmits relatively higherpressure fluid out of the second inlet/outlet through a second fluidconduit to an inlet/outlet of a hydraulic cylinder associated with thefirst clutch 62. Operation of the motor 480 in a second, oppositedirection tends to apply hydraulic pressure to the piston 254 of thesecond friction clutch 222 and to draw hydraulic fluid from the firstclutch 62. More specifically, operation of the motor 480 in the secondrotational direction operates the pump 482 in the second rotationaldirection so that the pump 482 draws hydraulic fluid into the secondinlet/outlet from the reservoir 474 and the inlet/outlet of thehydraulic cylinder associated with the first clutch 62 through thesecond fluid conduit and transmits relatively higher pressure fluid outof the first inlet/outlet through the first fluid conduit to theinlet/outlet of the hydraulic cylinder associated with the secondfriction clutch 222. Check valves or other one-way valves 490 areemployed in the hydraulic circuit to coordinate operation of the firstclutch 62 and the second friction clutch 222 in the desired manner whilestill permitting the pump 482 to draw hydraulic fluid from the reservoir474 when needed. In the example provided, a first one-way valve 490 isdisposed in the first fluid conduit between the inlet/outlet port of thehydraulic cylinder associated with the second friction clutch 222 andthe reservoir 474 and a second one-way valve 490 is disposed in thesecond fluid conduit between the inlet/outlet port of the hydrauliccylinder associated with the first clutch 62 and the reservoir 474.

Second Example

In FIG. 9, a portion of a second drive module 24 a constructed inaccordance with the teachings of the present disclosure is illustrated.The drive module 24 a can be generally similar to the drive module 24(FIG. 1), except for the construction of the two-speed planetarytransmission stage 60 a, the first clutch 62 a, the second clutch 64 a,and the park pawl mechanism 50 a.

With reference to FIG. 10, the two-speed planetary transmission stage 60a can include a second sun gear 110 a, a second planet carrier 114 a, aplurality of second planet gears 112 a, and a second ring gear 116 a.The second sun gear 110 a can be coupled to the shaft portion 88 of thesecond body member 86 of the first planet carrier 74 for rotationtherewith. Accordingly, it will be appreciated that the first planetcarrier 74 can be an output member of the input planetary stage (i.e.,the first reduction gearset 66), and that the second sun gear 110 a canbe an input member of an intermediate (or output) reduction gear set.The second planet carrier 114 a can comprise a plurality of second pins122 a and a second carrier body 120 a that can have first and secondannular plates that can be fixedly mounted to opposite ends of thesecond pins 122 a. Each of the second planet gears 112 a can be mountedon an associated one of the second pins 122 a and can be meshinglyengaged with the second sun gear 110 a and the second ring gear 116 a.If desired, a bearing 130 can be received between each of the secondpins 122 a and each of the second planet gears 112 a. The second planetcarrier 114 a, and more specifically, the second carrier body 120 a, canbe an output member of the two-speed planetary transmission stage 60 a.The carrier body 120 a of the second planet carrier 114 a can directlydrive the first spur gear 314 a.

With reference to FIG. 11, the first clutch 62 a can be any type ofclutch that can selectively couple the second ring gear 116 a to thesecond sun gear 110 a to lock the two-speed planetary transmission stage60 a (i.e., so that the two-speed planetary transmission stage 60 aoperates at a gear ratio of about 1:1). In the particular exampleprovided, the first clutch 62 a is generally similar to the first clutch62 (FIG. 4) except that the second clutch drum 176 a is coupled to thesecond ring gear 116 a (rather than to the second carrier body 120 a)for rotation therewith.

Similarly, the second clutch 64 a is configured to selectivelynon-rotatably couple the second ring gear 116 a (rather than the secondcarrier body 120 a) to the housing 40 a. In this regard, the second race236 a of the one-way clutch 220 a is non-rotatably coupled to the secondring gear 116 a, and the third clutch plates 260 a of the secondfriction clutch 222 a can be non-rotatably coupled to the second ringgear 116 a.

Returning to FIG. 9, the ratchet 452 a of the park pawl mechanism 50 acan be directly coupled to the first spur gear 314 a of the secondreduction gearset 68 a.

Third Example

In FIG. 12, a portion of a third drive module 24 b constructed inaccordance with the teachings of the present disclosure is illustrated.The drive module 24 b can be generally similar to the drive module 24(FIG. 1), except for the construction of the multi-speed transmission 44b.

The multi-speed transmission 44 b can comprise a two-speed planetarytransmission stage 60 b, a first clutch 62 b and a second clutch 64 b.Optionally, the multi-speed transmission 44 b can comprise one or morefixed reduction stages or gearsets, such as a first reduction gearset 66b and a second reduction gearset 68 b.

The first reduction gearset 66 b can couple the motor output shaft 56 tothe two-speed planetary transmission stage 60 b. In the exampleprovided, the first reduction gearset 66 b comprises a first spur gear70 b that is meshingly engaged to a second spur gear 500 that is coupledto a shaft member 502 for common rotation.

The two-speed planetary transmission stage 60 b can include a first sungear 110 b, a second sun gear 510, a plurality of first planet gears 112b, a plurality of compound planet gears 512, and a planet carrier 514.The first sun gear 110 b can be coupled to the shaft member 502 forcommon rotation. The second sun gear 510 can be disposed coaxially aboutthe shaft member 502. Each of the first planet gears 112 b can bemeshingly engaged with the first sun gear 110 b and can be journallysupported by the planet carrier 514. Each of the compound planet gears512 can be journally supported by the planet carrier 514 and can includea second planet gear 520, which can be meshingly engaged to one or moreof the first planet gears 112 b, and a third planet gear 522 that can bemeshingly engaged to the second sun gear 510 and coupled to itsassociated second planet gear 520 for common rotation. The planetcarrier 514 can be the output of the two-speed planetary transmissionstage 60 b.

The first clutch 62 b can be any type of clutch that can selectivelycouple the second sun gear 510 to the shaft member 502 for commonrotation. The second clutch 64 b can be any type of clutch or clutchesthat can be configured to selectively non-rotatably couple the secondsun gear 510 to the housing 40 a.

The second reduction gearset 68 b can include a third spur gear 530,which can be coupled to the planet carrier 514 for rotation therewith,and the second ring gear 116 that can be coupled to the differentialcase.

The two-speed planetary transmission stage 60 b can be operated in ahigh-speed forward mode in which the first clutch 62 b couples the shaftmember 502 to the second sun gear 510 and the second clutch 64 b doesnot couple the second sun gear 510 to the housing 40 a. Rotary powerproduced by the motor 42 (through rotation of the output shaft 56 in afirst rotational direction) is transmitted through the first reductiongearset 66 b to the shaft member 502, which drives both the first sungear 110 b and the second sun gear 510 (through the first clutch 62 b).Operation in this manner effectively locks the two-speed planetarytransmission stage 60 b so that the planet carrier 514 co-rotates withthe shaft member 502 to thereby drive the third spur gear 530 at a highspeed ratio.

The two-speed planetary transmission stage 60 b can also be operated ina low-speed forward mode in which the first clutch 62 b does not couplethe shaft member 502 to the second sun gear 510 and the second clutch 64couples the second sun gear 510 to the housing 40 a. Rotary powerproduced by the motor 42 (through rotation of the output shaft 56 in thefirst rotational direction) is transmitted through the first reductiongearset 66 b to the shaft member 502, which drives the first sun gear110 b. The planet carrier 514 is driven by the meshing action of thesecond planet gears 520 and the second sun gear 510, which drives thethird spur gear 530 at a low speed ratio.

The two-speed planetary transmission stage 60 b can be operated in alow-speed reverse mode in which the first clutch 62 b does not couplethe shaft member 502 to the second sun gear 510 and the second clutch 64b couples the second sun gear 510 to the housing 40 a.

The foregoing description of the embodiments has been provided forpurposes of illustration and description. It is not intended to beexhaustive or to limit the disclosure. Individual elements or featuresof a particular embodiment are generally not limited to that particularembodiment, but, where applicable, are interchangeable and can be usedin a selected embodiment, even if not specifically shown or described.The same may also be varied in many ways. Such variations are not to beregarded as a departure from the disclosure, and all such modificationsare intended to be included within the scope of the disclosure.

What is claimed is:
 1. A drive module comprising: an electric motor; adifferential assembly having a differential input member and a pair ofdifferential output members; a multi-speed transmission assemblytransmitting rotary power between the electric motor and thedifferential input member, the multi-speed transmission assemblycomprising a housing, a two-speed planetary transmission stage, a firstclutch, a second clutch and a transmission output member, the two-speedplanetary transmission stage having a first sun gear, a second sun gear,a plurality of first planet gears, a plurality of compound planet gearsand a planet carrier, the first sun gear being driven by the electricmotor, the first planet gears being meshingly engaged to the first sungear and journally supported by the planet carrier, each of the compoundplanet gears being journally supported by the planet carrier and havinga second planet gear, which is meshingly engaged to a corresponding oneof the first planet gears, and a third planet gear, which is meshinglyengaged to the second sun gear and coupled for rotation with anassociated one of the second planet gears, the first clutch beingconfigured to selectively couple the second sun gear to the first sungear for common rotation, the second clutch being configured toselectively couple the second sun gear to the housing, the transmissionoutput member being driven by the planet carrier and providing rotarypower to the differential input member; and a pair of axle shafts, eachof the axle shafts being coupled to an associated one of thedifferential output members for rotation therewith.
 2. The drive moduleof claim 1, wherein the multi-speed transmission assembly furthercomprises a fixed stage.
 3. The drive module of claim 2, wherein thefixed stage is disposed between the electric motor and the first sungear of the two-speed planetary transmission stage.
 4. The drive moduleof claim 3, wherein the fixed stage comprises another planet carrieronto which the first sun gear of the two-speed planetary transmissionstage is mounted.
 5. The drive module of claim 3, wherein the fixedstage comprises a first spur gear, which is coupled to an output shaftof the electric motor for rotation therewith, and a second spur gearthat is coupled to the first sun gear for common rotation.
 6. The drivemodule of claim 1, wherein the second clutch comprises a one-way clutchthat permits free rotation of the one of the planet carrier and the ringgear in a predetermined rotational direction.
 7. The drive module ofclaim 1, wherein the first and second clutches are disposed on a commonaxial end of the multi-speed transmission assembly.
 8. A drive modulecomprising: an electric motor; a differential assembly having adifferential input member and a pair of differential output members; amulti-speed transmission assembly transmitting rotary power between theelectric motor and the differential input member, the multi-speedtransmission assembly comprising a two-speed planetary transmissionstage, a first clutch, a second clutch and a transmission output member,the two-speed planetary transmission stage having a first planetarystage and a second planetary stage, the first planetary stage having aplurality of first planet gears, the second planetary stage having aplurality of second planet gears, each of the second planet gears beinga compound planet gear having a planet gear portion that is meshinglyengaged with a corresponding one of the first planet gears, the firstclutch being operable to selectively couple an input of the firstplanetary stage to an input of the second planetary stage, the secondclutch being configured to selectively operate the second planetarystage at a predetermined reduction ratio, the transmission output memberbeing driven by the second planetary stage and providing rotary power tothe differential input member; and a pair of axle shafts, each of theaxle shafts being coupled to an associated one of the differentialoutput members for rotation therewith; wherein the multi-speedtransmission assembly further comprises a fixed stage.
 9. The drivemodule of claim 8, wherein the fixed stage is disposed between theelectric motor and the input of the first planetary stage.
 10. The drivemodule of claim 9, wherein the fixed stage comprises a first planetcarrier onto which the input of the first planetary stage is mounted.11. The drive module of claim 9, wherein the fixed stage comprises afirst spur gear, which is coupled to an output shaft of the electricmotor for rotation therewith, and a second spur gear that is coupled tothe input of the first planetary stage for common rotation.
 12. Thedrive module of claim 8, wherein the second clutch comprises a one-wayclutch.
 13. The drive module of claim 8, wherein the first and secondclutches are disposed on a common axial end of the multi-speedtransmission assembly.